Battery constructed with indexing conveyor system and continuous terminal chain

ABSTRACT

A method of constructing a battery using a control unit to cause battery components to be drawn through an automated conveyor system and between indexed positions on the conveyor system is provided. Positive terminals for a battery are attached to a first carrier strip having indexing apertures. Negative terminals for a battery are attached to a second carrier strip having indexing apertures. Spools, controlled by control unit, are engaged in the indexing apertures of the first and second carrier strips and rotated for movement of carrier strips and terminals through indexed construction positions.

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates to processes for constructing and indexing storage batteries.

2. Description of the Related Art

Current construction methods of storage batteries involve using fixtures, human labor, and some system automation to build a battery from its component parts. U.S. Pat. No. 4,342,342 issued to Wheadon shows battery plates prepared and cured on a battery assembly line, but then removed from the assembly line, to be later assembled into a complete battery. These types of production methods are disadvantageous for several reasons. One of the problems is that they are inefficient because of the amount of labor involved and a complete battery can not be produced without extensive human labor and oversight. Also, there exists no indexing system, which again, slows the process of creating a complete battery by not having an automatic system to more quickly move a battery under construction from one process to the next process. Another problem is that these methods are costly because of the amount of time and human labor and oversight needed to build a battery wherein the construction process is not indexed automatically such that a battery under construction can be moved automatically from one process to the next.

There is therefore a need for an improved process of building batteries that minimizes or eliminates one or more of the problems set forth above.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a solution to one or more of the above mentioned problems. In one aspect of the invention, an automatic conveyor system controlled by a control unit is provided to construct a storage battery. This system includes spools in which the carrier strip is engaged such that the terminals, which are attached to the carrier strip, are drawn forward through the construction process stages. This also allows indexing of each battery under construction by an indexing unit. The carrier strip is engaged in the spools via apertures in the carrier strip. One advantage of this system is the amount of manual labor required to monitor the batteries through their construction process, as well as constructing the batteries themselves, is reduced because the batteries can be constructed and indexed by the automated system.

According to a first aspect of the invention, a method is provided, involving the steps of providing a positive terminal for a battery wherein the positive terminal is attached to a first carrier strip having indexing apertures, providing a negative terminal for a battery wherein the negative terminal is attached to a second carrier strip having indexing apertures, and rotating spools engaged in the indexing apertures of the first and second carrier strips to allow movement.

In another aspect of the invention, positive terminals and negative terminals are attached in a continuous chain, positive terminal to positive terminal and negative terminals to negative terminals. One advantage of this configuration is that it further speeds the construction process in two ways. First, reducing the amount of empty space between batteries under construction reduces the amount of time needed to move a battery from one construction stage to the next construction stage. Second, reducing the amount of empty space allows numerous batteries through a process simultaneously (i.e. several batteries can be in an extraction chamber simultaneously).

An apparatus for indexing a battery through the construction process is also presented.

Other features, objects, and advantages will become apparent to one of ordinary skill from the following detailed description and accompanying drawings illustrating the invention by way of example but not by way of limitation.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a battery of a type that can be indexed by a process according to the invention.

FIG. 2 is a perspective view of a preferred embodiment for indexing for batteries according to the invention.

FIG. 3 is a simplified plan of the method according to the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings wherein like reference numerals are used to identify identical components in the various views, FIG. 1 illustrates a storage battery 10, in various stages of construction, all or part of which may be constructed using the improved automated system. To fully appreciate the advantages of the present invention, a brief description of the product made thereby, and its component parts will be set forth. The battery 10 may be connected with other batteries or may be used as an individual unit. It may be used for portable or stationary electrical and/or electronic devices. An exploded view of an initial phase of construction is designated 10 _(A), an intermediate phase of construction is designated 10 _(B), and a completed phase of construction is designated 10 _(C). FIG. 1 shows a plurality of bicells 12 with exposed conductive grids 14, positive and negative terminals 16 _(a), 16 _(b), a cover strip 18, and packaging 20 with hot melt adhesive layer 22 along the edges 26, 28, 29 of packaging.

Bicells 12 may comprise conventional bicells known to those of ordinary skill in the art, for example as seen by reference to U.S. Pat. No. 6,063,519, issued to Barker, et al., hereby incorporated by reference. In the illustrated embodiment, a plurality of bicells 12 are connected in a parallel electrical relationship. Exposed grids 14 are current carriers.

Cover strip 18 is made of the same material as the corresponding terminal (positive or negative) 16 _(a), 16 _(b) and is placed above grids 14 or below grids 14, dependent upon whether terminals 16 _(a), 16 _(b) are welded above or below grids 14. Use of cover strip 18 aids in ultrasonic welding of exposed grids 14 to terminals 16 _(a), 16 _(b) because it protects the relatively fragile exposed grids 14 during the welding.

Bicells 12 are enclosed in packaging 20. Packaging 20 may comprise a single sheet which is folded to enclose bicells 12. Packaging 20 may be a type of laminated, aluminized flexible material which contains four layers. The outside layer exposed to the environment is an electrical insulating material, for example, a polyester. The next underlying layer is metallic, for example, aluminum. This metallic layer reduces or eliminates the amount of moisture outside of packaging 20 to which the battery is exposed (i.e., provides a bidirectional moisture barrier). The third layer is of the same material as the outside layer. The fourth layer, layer 22, comprises an adhesive such as a conventional sealing hot melt adhesive, for example, ethylene acrylic acid (EAA). In one embodiment, a part of a sheet of packaging 20 is placed under battery 10 and a remaining part of the packaging 20 is folded over bicells 12 such that hot melt adhesive layer 22 may come in contact with itself at a first end 28, a second end 29, and the edge 26 opposite the packaging fold 24.

In the illustrated embodiment shown in FIG. 1, terminal 16 _(b) is placed above the plurality of bicells 12, while terminal 16 _(a) is placed below the plurality of bicells 12. In a preferred embodiment, terminals 16 _(a), 16 _(b) are located in the same plane (either both placed above the plurality of bicells 12 or placed below the plurality of bicells 12). This arrangement is preferred because it eases manufacturing, as will be described in detail below. Overall, automatically moving battery 10 through its various stages of construction, indexing battery 10 as battery 10 passes through construction stages, presents manufacturing benefits and challenges. The invention overcomes these and other problems.

FIG. 2 illustrates an embodiment of an automatic indexing conveyor system 30. Conveyor system 30 includes a control unit 32, indexed construction positions 34 _(n)(where n is an integer ranging from one to seven in the illustrated embodiment), an indexing unit 36, carrier strips 38 that may include apertures 40, spools 42 that may include radial members 44, conveyor belts 46 _(a), 46 _(b), cutters 48 _(a), 48 _(b), a reel 50 of packaging 20 and an extraction chamber 52.

Control unit 32 controls conveyor system 30. Conveyor system 30 moves each positive terminal 16 _(a) and each negative terminal 16 _(b) pre-determined distances to indexed construction positions 34 _(n). Control unit 32 may control the pre-determined distances to which the terminals 16 _(a,) 16 _(b) are moved.

Indexing unit 36 is controlled by control unit 32. Indexing unit 36, controlled by control unit 32, may control the pre-determined distances to which terminals 16 _(a), 16 _(b) are moved. Indexing unit 36 allows battery 10 to be located and indexed at each position 34 _(n) of construction.

Carrier strips 38 _(a), 38 _(b) draw terminals 16 _(a), 16 _(b) through indexing construction positions 34 _(n). Positive terminal 16 _(a) is attached to carrier strip 38 _(a) and negative terminal 16 _(b) is attached to carrier strip 38 _(b). As carrier strips 38 _(a), 38 _(b) are drawn through positions 34 _(n), terminals 16 _(a), 16 _(b) which are attached to carrier strips 38 _(a), 38 _(b), respectively, are also drawn through positions 34 _(n).

Carrier strips 38 _(a), 38 _(b) are drawn through positions 34 _(n) by apertures 40 in carrier strips 38 _(a), 38 _(b) engaged in spools 42. Apertures 40 may be circular or elliptical in shape. Each aperture 40 may be a uniform distance away from the adjacent apertures 40. The number of spools 42 may be varied. Spools 42 may be the same size. Spools 42 may be spherical in shape. Spools 42 may include radial members 44. Radial members 44 may engage apertures 40 such that as spool 42 rotates, each individual aperture 40 is fed over a radial member 44. Rotation of spools 42 is controlled by control unit 32. This rotation moves carrier strips 38 _(a), 38 _(b) through conveyor system 30, thereby, moving terminals 16 _(a), 16 _(b). In the illustrated embodiment, bicells 12 have been placed in electrical connection with positive terminal 16 _(a) and negative terminal 16 _(b). Further, bicells 12 may be ultrasonically welded to terminals 16 _(a), 16 _(b). As terminals 16 _(a), 16 _(b) are drawn forward, all attached accompanying parts of battery 10, including bicells 12 and/or packaging 20 are also drawn forward through conveyor system 30.

Conveyor belts 46 _(a), 46 _(b) may located between spools 42 and carrier strips 38 _(a), 38 _(b) to aid in drawing terminals 16 _(a), 16 _(b) through indexed construction positions 34 _(n). Conveyor belts 46 _(a), 46 _(b) may include indentations or apertures (not shown) to aid in smoother movement of carrier strips 38 _(a), 38 _(b).

Each set of terminals 16 _(a), 16 _(b) may be attached to both the previous set of terminals and the subsequent set of terminals such that terminals 16 _(a), 16 _(b) are in a continuous chain. A first positive terminal 16 _(a) may be attached to a second positive terminal, which in turn is attached to a third positive terminal, thereby creating the continuous chain. Likewise, a first negative terminal 16 _(b) may be attached to a second negative terminal, which in turn is attached to a third positive terminal, thereby creating a continuous chain. This is advantageous in that more battery component sets can be moved through stages of the construction process more quickly. For example, several index construction positions 34 ₁₋₄ can be located within extraction chamber 52 simultaneously. Cutters 48 _(a), 48 _(b) are provided to sever or separate the sets of terminals 16 _(a), 16 _(b) connected to adjacent terminals 16 _(a), 16 _(b). Terminals 16 _(a), 16 _(b) must be separated from adjacent terminals 16 _(a), 16 _(b) to finish construction process of a single battery 10.

Reel 50 of packaging material 20 is provided to aid in construction of battery 10. Sheet of packaging 20 from reel 50 is unrolled a pre-determined amount. This action is controlled by control unit 32. Packaging 20 is moved over battery components such that bicells 12 are covered. Packaging 20 is cut by a cutter (not shown) a pre-determined amount such that enough packaging 20 material is left so packaging 20 is folded by a folding mechanism (not shown) such that bicells 12 are enclosed in an envelope of packaging. Control unit 32 controls the packaging cutter and folding mechanism.

Referring now to FIGS. 2 and 3, the operation of the automated indexing, construction mechanism is illustrated in one embodiment. In step 54, a positive terminal 16 _(a) attached to carrier strip 38 _(a) having apertures 40 is provided. In step 56, a negative terminal 16 _(a) attached to carrier strip 38 _(b) having apertures 40 is provided. Bicells 12 may be placed on terminals 16 _(a), 16 _(b). Additionally, exposed grids 14 of bicells 12 may be ultrasonically welded to terminals 16 _(a), 16 _(b). In step 58, spools 42 engaged in apertures 40 of carrier strips 38 _(a), 38 _(b) rotate and move carrier strips 38 _(a), 38 _(b)(and attached terminals 16 _(a), 16 _(b) and bicells 12) through conveyor system 30, and indexed construction positions 34 _(n). Rotating spools 42, controlled by control unit 32, first move carrier strips 38 _(a), 38 _(b), terminals 16 _(a), 16 _(b) and bicells 12 to indexed construction position 34 ₁. At position 34 ₁, carrier strips 38 _(a), 38 _(b), terminals 16 _(a), 16 _(b), and bicells 12 are moved through extraction chamber 52. The process of extraction involves removal of a plasticizer to create micropores, which are subsequently backfilled with an electrolyte. Extraction involves exposing bicells 12 to a fluid, such as dry, heated air. This can be accomplished in a controlled environment (such as a glove box or drying oven or other extraction chamber) or in a non-controlled environment. Extraction processes are known in the art.

Next, conveyor system 30, controlled by control unit 32, moves sets of carrier strips 38 _(a), 38 _(b), terminals 16 _(a), 16 _(b), and bicells 12 to indexed construction position 34 ₅. At indexed construction position 34 ₅, control unit 32 causes terminals 16 _(a), 16 _(b) to be cut by cutters 48 _(a), 48 _(b), separating each set of terminals 16 _(a), 16 _(b) from the preceding and subsequent sets of terminals 16 _(a), 16 _(b). Cutters 48 _(a), 48 _(b) are controlled by control unit 32.

Next, conveyor system 30, controlled by control unit 32, moves sets of carrier strips 38 _(a), 38 _(b), terminals 16 _(a), 16 _(b), and bicells 12 through indexed construction position 34 ₆. At index construction position 34 ₆, control unit 32 causes a sheet of packaging 20 to be unrolled from a reel 50 a pre-determined amount. Packaging material 20 is moved over battery components such that bicells 12 are covered. Packaging sheet 20 is cut by a cutter (not shown) a pre-determined amount, leaving enough material that bicells 12 are covered underneath. Packaging 20 is folded by a folding mechanism (not shown) such that bicells 12 are enclosed in an envelope of packaging 20.

Then conveyor system 30, controlled by control unit 32, moves sets of carrier strips 38 _(a), 38 _(b), terminals 16 _(a), 16 _(b), and bicells 12 to indexed construction position 34 ₇. At position 34 ₇ carrier strips 38 _(a), 38 _(b) are removed 66 from terminals 16 _(a), 16 _(b).

In another embodiment, battery 10 components entering extraction chamber 52 also include packaging 20 which envelopes bicells 12 as described above. Packaging has been cut by a cutter (not shown) at fold 24. Sides 28, 29 of packaging 20 may have been sealed with a heated platens. This results in two sides 24, 26 of packaging open for fluid (heated air) of the extraction chamber 52 to flow over bicells 12.

While the invention has been disclosed in terms of specific embodiments thereof, it is not intended to be limited thereto, but rather only to the extent set forth hereafter in the claims which follow. 

1. A method, comprising the steps of: (A) providing a positive terminal for a battery wherein said positive terminal is attached to a first carrier strip having indexing apertures, (B) providing a negative terminal for a battery wherein said negative terminal is attached to a second carrier strip having indexing apertures, (C) rotating spools engaged in said indexing apertures for movement of a battery through an extraction chamber, and providing said spools with radial members engaged in said indexing apertures; and (D) removing said first carrier strip from said positive terminal and removing said second carrier strip from said negative terminal.
 2. (canceled)
 3. The method of claim 1, wherein said positive terminal is a first positive terminal, further comprising attaching a second positive terminal to said first positive terminal.
 4. The method of claim 3, further comprising the step of severing said first positive terminal from said second positive terminal.
 5. (canceled)
 6. The method of claim 1, further comprising the steps of: (A) placing on said positive terminal and said negative terminal a plurality of bicells; and (B) welding said plurality to said positive terminal and said negative terminal.
 7. The method of claim 1, wherein said providing said positive terminal step includes the substep of providing a packaging having a sealed pair of opposing sides and an open pair of opposing sides. 